Master pallet shipper

ABSTRACT

The present disclosure relates generally to a pallet shipper. More particularly, the present disclosure relates to an insulated pallet shipper for containers. Specifically, the present disclosure relates to a fully recyclable insulated pallet shipper with an outer shroud, a top assembly, a bottom assembly, a plurality of insulating panels, a plurality of thermal resistive assemblies, and a plurality of thermal buffer pads.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser. No. 67/766,085 filed on Oct. 1, 2018; the disclosure of which is incorporated herein by reference.

BACKGROUND Technical Field

The present disclosure relates generally to a pallet shipper. More particularly, the present disclosure relates to an insulated pallet shipper for containers. Specifically, the present disclosure relates to a fully recyclable insulated pallet shipper.

Background Information

Generally, temperature sensitive materials, such as foods, pharmaceuticals, organs, blood, biologic materials, chemicals, and the like, are shipped in insulated shipping containers.

Some typical insulated shipping containers include molded, expanded polystyrene coolers, as well as multi-part panel systems incorporating two, four or even six panels of material constructed from rigid pre-fabricated panels of expanded polystyrene, semi-rigid panels of cellulose, or similar mat fiber panels, encapsulated in a polyethylene film or the like. Other typical insulated shipping containers include flexible insulated container liners made entirely of polyethylene and flexible foams and/or semi-rigid panels of cellulose, cotton, or similar mat fiber panels. Typical insulated shipping liners are approximately one fourth of an inch thick and have a density of approximately one pound per cubic foot.

One drawback associated with the above-mentioned typical insulated containers includes that they are not are not readily accepted in various recycling programs, including municipal recycling programs, because, among other reasons, the comingling of the materials of the typical insulated shipping containers is not readily recyclable (e.g. the comingling of multiple categories of polyethylene or polyethylene and paper combined). This leads to another drawback which includes that the insulated shipping containers typically need to be retrieved at the end of the transit period instead of being recycled.

SUMMARY

Further, many shipping containers are not well suited for transporting large amounts effectively. As such, there exists a need for an insulated shipping container that may be pallet sized in order to carry larger loads with minimal temperature fluctuation.

In one aspect, an exemplary embodiment of the present disclosure may provide an insulated pallet shipper apparatus wherein: the apparatus has a width of about 40 inches; the apparatus has a length of about 48 inches; the apparatus has a height of about 50 inches; the apparatus is six sided and closed and the apparatus is adapted to sit on a pallet for transportation. This exemplary embodiment or another exemplary embodiment may provide the entire apparatus is fully recyclable.

In one aspect, an exemplary embodiment of the present disclosure may provide a fully insulated and fully recyclable apparatus comprising: an outer shroud; a top assembly; a bottom assembly; a plurality of insulating panels; a plurality of thermal resistive assemblies; and a plurality of thermal buffer pads. This exemplary embodiment or another exemplary embodiment provides the plurality of insulating panels are filled with loose fill cellulose insulation with a settled distance of about 3.5 pounds PCF or greater free of fire retardant additives or poly binders. This exemplary embodiment or another exemplary embodiment provides the plurality of insulating panels each have a wall thickness of two inches or greater. This exemplary embodiment or another exemplary embodiment provides the plurality of thermal resistive assemblies are non-vented. This exemplary embodiment or another exemplary embodiment provides the thermal buffer pads are double walled cardboard. This exemplary embodiment or another exemplary embodiment provides the plurality of thermal resistive assemblies each contain at least one biodegradable and otherwise recyclable gel pack. This exemplary embodiment or another exemplary embodiment provides top assembly includes: a top cap, at least one top insulating panel, a top plug, at least one top thermal resistive assembly, and at least one top thermal buffer pad. This exemplary embodiment or another exemplary embodiment provides the top cap is fixedly attached to a top insulating panel, the top insulating panel is fixedly attached to the top plug, the top plug is fixedly attached to a top thermal buffer pad. This exemplary embodiment or another exemplary embodiment provides the bottom assembly includes: a bottom cap, at least one bottom insulating panel, at least one bottom thermal resistive assembly, and at least one bottom thermal buffer pad. This exemplary embodiment or another exemplary embodiment provides the bottom cap is fixedly attached to a bottom insulating panel, the bottom insulating panel is fixedly attached to a top thermal buffer pad. This exemplary embodiment or another exemplary embodiment provides the outer shroud is made of double walled cardboard. This exemplary embodiment or another exemplary embodiment provides the outer shroud comprises four sides, each side containing: at least one side insulating panel, at least one side thermal resistive assembly, and at least one side thermal buffer pad. This exemplary embodiment or another exemplary embodiment provides wherein the outer shroud is fixedly attached to a side insulating panel, the side insulating panel is fixedly attached to a thermal resistive assembly and the thermal resistive assembly is fixedly attached to a side thermal buffer pad. This exemplary embodiment or another exemplary embodiment provides the outer shroud is fixedly attached to the bottom assembly. This exemplary embodiment or another exemplary embodiment provides the outer shroud is not in fixed engagement with the top assembly. This exemplary embodiment or another exemplary embodiment provides a chamber operative to accept cargo is formed by the attachment of the outer shroud to the bottom assembly. This exemplary embodiment or another exemplary embodiment provides at least one thermal resistive assembly is located within the chamber. This exemplary embodiment or another exemplary embodiment provides the plurality of thermal resistive assemblies each contain at least one biodegradable and recyclable gel pack. This exemplary embodiment or another exemplary embodiment provides the apparatus is operative to carry cargo that is desired to be kept at a near constant temperature. This exemplary embodiment or another exemplary embodiment provides the apparatus is operative to hold the cargo in a temperature range of about 2 degrees Celsius to about 8 degrees Celsius for over 120 hours.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

A sample embodiment of the disclosure is set forth in the following description, is shown in the drawings and is particularly and distinctly pointed out and set forth in the appended claims. The accompanying drawings, which are fully incorporated herein and constitute a part of the specification, illustrate various examples, methods, and other example embodiments of various aspects of the disclosure. It will be appreciated that the illustrated element boundaries (e.g., boxes, groups of boxes, or other shapes) in the figures represent one example of the boundaries. One of ordinary skill in the art will appreciate that in some examples one element may be designed as multiple elements or that multiple elements may be designed as one element. In some examples, an element shown as an internal component of another element may be implemented as an external component and vice versa. Furthermore, elements may not be drawn to scale.

FIG. 1 is a top right isometric perspective view of an exemplary master pallet shipper apparatus on top of a pallet.

FIG. 1A is a top right isometric partially exploded perspective view of the exemplary master pallet shipper apparatus.

FIG. 1B is a bottom right isometric partially exploded perspective view of the exemplary master pallet shipper apparatus.

FIG. 1C is a further top right exploded view of the exemplary master pallet shipper apparatus.

FIG. 2 is a rear side elevation view of the exemplary master pallet shipper apparatus.

FIG. 3 is a right side elevation view of the exemplary master pallet shipper apparatus.

FIG. 4 is a front right section view of the exemplary master pallet shipper apparatus.

FIG. 5 is a front right perspective view of an exemplary insulating panel base of the exemplary master pallet shipper apparatus.

FIG. 6 is a front right perspective view of an assembled exemplary baffle assembly of the exemplary master pallet shipper apparatus.

FIG. 7 is a front right perspective view of an insulating panel cover of the exemplary master pallet shipper apparatus.

FIG. 8A is a front right perspective view of the insulating panel base with the baffle assembly inserted into the cover of the exemplary master pallet shipper apparatus.

FIG. 8B is a front right perspective view of the insulating panel base with the baffle assembly inserted and packing material inserted into the cover of the exemplary master pallet shipper apparatus.

FIG. 8C is a front right perspective view of the insulating panel being assembled with the cover.

FIG. 9 is a front right perspective view of a gel pack insert grid of the exemplary master pallet shipper apparatus.

FIG. 10A is a front right perspective view of two gel pack insert grids in a gel pack insert panel of the exemplary master pallet shipper apparatus.

FIG. 10B is a front right perspective view of the gel pack insert panel being assembled.

FIG. 11 is a front plan view of a single thickness corrugated cardboard.

FIG. 12 is a front plan view of double thickness corrugated cardboard along line 12-12 in FIG. 4.

FIG. 13 is a front plan view of triple thickness corrugated cardboard taken along line 13-13 in FIG. 9.

FIG. 14 is a diagrammatic section view taken along line 14-14 in FIG. 3.

FIG. 15 is a diagrammatic section view taken along line 15-15 in FIG. 2.

FIG. 16 is a diagrammatic section view taken along line 16-16 in FIG. 2.

FIG. 17 is a graphical representation showing the results of the exemplary apparatus.

Similar numbers refer to similar parts throughout the drawings.

DETAILED DESCRIPTION

A new apparatus 10 is depicted in the present disclosure and throughout FIGS. 1-16. Apparatus 10 is a new and improved apparatus for insulating loads to be put on a pallet 12, as will be discussed hereafter. In an exemplary embodiment the apparatus is designed to fit on a standard 48″ L×40″ W×50″ H pallet, though in further embodiments the design may be modified to fit any size pallet, or multiple pallets attached together.

Referring specifically to FIG. 1, a top right isometric perspective view of the exemplary master pallet shipper apparatus 10 on top of the pallet 12 is shown. The apparatus 10 has a body which includes a top side 10A, a bottom side 10B that is vertically disposed from the top side 10A, a front side 10C that is longitudinally disposed from a back side 10D, and a first side 10E that Is transversely opposed to a second side 10F. All of these sides are merely outer surfaces and the inside of the apparatus will be described with reference to the further figures. The apparatus 10 is secured to the pallet 12 via an attachment mechanism 14. In the exemplary embodiment the attachment mechanism 14 may be a plurality of straps but in further embodiments the attachment mechanism 14 may be any such similar situated member.

In one embodiment, the top side 10A, bottom side 10B, front side 10C, back side 10D, first side 10E and second side 10F are all made of corrugated cardboard. Further, the front side 10C, back side 10D, first side 10E and second side 10F may be made of one solitary member or may be separate pieces, as will be discussed later.

Referring now to FIG. 1A, a top right isometric partially exploded perspective view of the exemplary master pallet shipper apparatus 10 is shown. The top side 10A has been exploded away and the constituents within have been shown in its various parts. These various parts within the top of the exemplary embodiment from top to bottom include: a top cap 16, a top insulating panel 18, a top plug 20, a top gel pack assembly 22, and a top thermal buffer pad 24. While gel pack assemblies are used and discussed herein, in an exemplary embodiment it may be any such thermal resistive assembly that is operative to hold within it material or materials that are recyclable and resist changes in temperature.

The top cap 16 has a body with a top surface 16A that is commiserate with the top side 10A and an underside 16B that is on the direct underside of the top surface 16A. As such, the top cap 16 is generally hollow in nature in that it does not have a solid bottom, merely the underside 16B on the other side of the top surface 16A. Further, the top cap 16 has a front side 16C which is longitudinally disposed from a back side 16D, and a first side 16E that Is transversely opposed to a second side 16F. The front side 16C and back side 16D have joints 16G that in an exemplary embodiment are created by folding in a portion of the sides 16E, 16F and gluing them to create the top cap 16. In an exemplary embodiment, the top cap 16 is made of single wall corrugated cardboard though thicknesses may vary based on load amount, thermal resistivity, ultimate pricing, and stacking concerns.

The top insulating panel 18 directly abuts the underside 16B at a top 18A of the top insulating panel 18. The top insulating panel 18 further has a bottom side 18B that is vertically disposed from the top side 18A. Further, the top insulating panel 18 has a front side 18C which is longitudinally disposed from a back side 18D, and a first side 18E that Is transversely opposed to a second side 18F. In an exemplary embodiment, the top insulating panel 18 is made of single wall corrugated cardboard though thicknesses may vary based on load amount, thermal resistivity, ultimate pricing, and stacking concerns.

The top plug 20 directly abuts the bottom 18B of the top insulating panel 18 at a top 20A of the top plug 20. The top plug 20 further has a bottom side 20B that is vertically disposed from the top side 20A. Further, the top plug 20 has a front side 20C which is longitudinally disposed from a back side 20D, and a first side 20E that Is transversely opposed to a second side 20F. In an exemplary embodiment, the top plug 20 is made of single wall corrugated cardboard though thicknesses may vary based on load amount, thermal resistivity, ultimate pricing, and stacking concerns.

The top gel pack assembly 22 directly abuts the bottom 20B of the top plug 20 at a top 22A of the top gel pack assembly 22. The top gel pack assembly 22 further has a bottom side 22B that is vertically disposed from the top side 22A. Further, the top gel pack assembly 22 has a front side 22C which is longitudinally disposed from a back side 22D, and a first side 22E that Is transversely opposed to a second side 22F. It should be noted that the gel pack assembly 22 is free of any vents in the exemplary embodiment. In further embodiments, vents may be present. In an exemplary embodiment, the top gel pack assembly 22 is made of single wall corrugated cardboard though its thicknesses may vary based on load amount, thermal resistivity, ultimate pricing, and stacking concerns.

The top thermal buffer pad 24 directly abuts the bottom 22B of the top gel pack assembly 22 at a top 24A of the top thermal buffer pad 24. The top thermal buffer pad 24 further has a bottom side 24B that is vertically disposed from the top side 24A. Further, the top thermal buffer pad 24 has a front side 24C which is longitudinally disposed from a back side 24D, and a first side 24E that Is transversely opposed to a second side 24F. In an exemplary embodiment, the top thermal buffer pad is made of double wall corrugated cardboard though thicknesses may vary based on load amount, thermal resistivity, ultimate pricing, and stacking concerns.

FIGS. 1B-C show is a further top right exploded view of the exemplary master pallet shipper apparatus. In this view, various layers are shown removed from the main body of the apparatus at the bottom. As such, one sees the similar exploded view as is seen in FIG. 1A, but the sides are partially deconstructed to view their inner contents. As can be seen, the bottom side 10B is constructed similarly to the top side 10A, where the bottom side 10B from bottom to top includes: a bottom cap 26, a bottom insulating panel 28, a bottom gel pack 30 and a bottom thermal buffer pad 34.

The bottom cap 26 has a body with a bottom surface 26B that is commiserate with the bottom side 10B and a bottom side 26B that is on the direct underside of the top surface 26A. As such, the bottom cap 26 is generally hollow in nature in that it does not have a solid top, merely the top surface 26A on the other side of the bottom surface 26B. Further, the bottom cap 26 has a front side 26C which is longitudinally disposed from a back side 26D, and a first side 26E that Is transversely opposed to a second side 26F. The front side 26C and back side 26D have joints 26G that in an exemplary embodiment are created by folding in a portion of the sides 26E, 26F and gluing them to create the bottom cap 26. In an exemplary embodiment, the bottom cap 26 is made of single wall corrugated cardboard though thicknesses may vary based on load amount, thermal resistivity, ultimate pricing, and stacking concerns.

In a further embodiment, the bottom cap 26 may be a wall constructed from multiple layers of multi-wall corrugated fiberboard sheets of at least 1″ in height. This bottom wall cap 26 may provide additional trapped air space between the base coolant members and the temperature sensitive cargo and provide an improved thermal buffer at the bottom of the chamber where internal temperatures may be lower.

The bottom insulating panel 28 directly abuts the top side 26A at a bottom 28B of the bottom insulating panel 28. The bottom insulating panel 28 further has a top side 28A that is vertically disposed from the bottom side 28B. Further, the bottom insulating panel 28 has a front side 28C which is longitudinally disposed from a back side 28D, and a first side 28E that Is transversely opposed to a second side 28F. In an exemplary embodiment, the bottom insulating panel 28 is made of single wall corrugated cardboard though thicknesses may vary based on load amount, thermal resistivity, ultimate pricing, and stacking concerns.

The bottom gel pack assembly 30 directly abuts the top 28A of the bottom insulating panel 28 at a bottom 30B of the bottom gel pack assembly 30. The bottom gel pack assembly 30 further has a top side 30A that is vertically disposed from the bottom side 30B. Further, the bottom gel pack assembly 30 has a front side 30C which is longitudinally disposed from a back side 30D, and a first side 30E that Is transversely opposed to a second side 30F. It should be noted that the gel pack assembly 30 is free of any vents in the exemplary embodiment. In further embodiments, vents may be present. In an exemplary embodiment, the bottom gel pack assembly 30 is made of single wall corrugated cardboard though thicknesses may vary based on load amount, thermal resistivity, ultimate pricing, and stacking concerns.

The bottom thermal buffer pad 32 directly abuts the top 30A of the bottom gel pack assembly 30 at a bottom 32B of the bottom thermal buffer pad 32. The bottom thermal buffer pad 32 further has a top side 32A that is vertically disposed from the bottom side 32B. Further, the bottom thermal buffer pad 32 has a front side 32C which is longitudinally disposed from a back side 32D, and a first side 32E that Is transversely opposed to a second side 32F. In an exemplary embodiment, the bottom thermal buffer pad is made of double wall corrugated cardboard though thicknesses may vary based on load amount, thermal resistivity, ultimate pricing, and stacking concerns.

Referring now to FIG. 1C, is a further top right exploded view of the exemplary master pallet shipper apparatus is shown. In this view, various layers are shown removed from the main body of the apparatus at the bottom. As such, one sees the similar exploded view as is seen in FIG. 1A, but the sides are partially deconstructed to view their inner contents. Generally, the front side 10C, back side 10D, first side 10E and second side 10F comprise similar inside contents. The sides 10C, 10D, 10E, 10F each contain, working from the outside surface to the inside, outer shrouds 34, 42, 50, 58, side insulating panels 36, 44, 52, 60, side gel pack assemblies 38, 46, 54, 62, and thermal buffer pads 40, 48, 56, 64.

The outer shrouds 34, 42, 50, 58 each have a body with a respective top surface 34A, 42A, 50A, 58A, that is in contact with the top cap 16 at its underside 16B. The outer shrouds 34, 42, 50, 58 are positioned 90 degrees to one another and form a rectangle or square shape. Further, the outer shrouds 34, 42, 50, 58 each have a respective bottom surface 34B, 42B, 50B, 58B that is vertically disposed from the corresponding respective top surface 34A, 42A, 50A, 58A, that is in contact with the bottom cap 26 at its top side 26A. In the exemplary embodiment, only two outer shrouds may be implored covering a two sides each, such as 34, 50 and 42, 58 or 42, 50 and 58, 34. In such a case there are reinforced regions R1 and R2. In further embodiments the outer shroud may be one unibody piece with no reinforced regions or four individual pieces with four reinforced regions.

The outer shrouds 34, 42, 50, 58 further have a front side or outer side 34C, 42D, 50E, 58F which is commiserate with their respective side 10C, 10D, 10E or 10F and a back side or inner side 34D, 42C, 50F, 58E which is longitudinally disposed from a front side 34C, 42D, 50E, 58F, and a first side 34E, 42F, 50C, 58D that is transversely opposed to a second side 34F, 42E, 50D, 58C. The front side 34C, 42D, 50E, 58F is abutted against the respective sides 16C, 16D, 16E, 16F of the top cap 16 and the respective sides 26C, 26D, 26E, 26F of the bottom cap 26. In the exemplary embodiment, the outer shrouds 34, 42, 50, 58 are made of double wall corrugated cardboard, though thicknesses may vary based on load amount, thermal resistivity, ultimate pricing, and stacking concerns.

The back side 34D of the outer shroud 34 abuts and is operatively connected to the first side 50C of the outer shroud 50 and the second side 58C of the outer shroud 58. While the back side 42C of the outer shroud 50 abuts and is operatively connected to the first side 50D of the outer shroud 50 and the second side 58D of the outer shroud 58.

The side insulating panels 36, 44, 52, 60 each have a body with a respective top surface 36A, 44A, 52A, 60A, that is in contact with the top insulating panel 18 at its underside 18B. The side insulating panels 36, 44, 52, 60 are positioned 90 degrees to one another and form a rectangle or square shape. Further the outer shroud has a respective bottom surface 36B, 44B, 52B, 60B that is vertically disposed from the corresponding respective top surface 36A, 44A, 52A, 60A, that is in contact with the bottom insulating panel 28 at its top side 28A.

The side insulating panels 36, 44, 52, 60 further have a front side or outer side 36C, 44D, 52E, 60F and a back side or inner side 36D, 44C, 52F, 60E which is longitudinally disposed from a front side 36C, 44D, 52E, 60F, and a first side 36E, 44F, 52C, 60D that is transversely opposed to a second side 36F, 44E, 52D, 60C. The front side 36C, 44D, 52E, 60F is abutted against the respective rear sides 34D, 42C, 50F, 58E of the outer shrouds 34, 42, 50, 58. In the exemplary embodiment, the side insulating panels 36, 44, 52, 60 is made of single walled corrugated cardboard, though thicknesses may vary based on load amount, thermal resistivity, ultimate pricing, and stacking concerns.

The back side 36D of the side insulating panel 36 abuts and is operatively connected to the first side 52C of the side insulating panel 36 and the second side 60C of the side insulating panel 60. While the back side 44C of the side insulating panel 52 abuts and is operatively connected to the first side 52D of the side insulating panel 52 and the second side 60D of the side insulating panel 60.

The side gel pack assemblies 38, 46, 54, 62 each have a body with a respective top surface 38A, 46A, 54A, 62A, that is in contact with the top plug 20 and top gel pack assembly 22 at their undersides 20B, 22B. The side gel pack assemblies 38, 46, 54, 62 are positioned 90 degrees to one another and form a rectangle or square shape. Further the side insulating panel has a respective bottom surface 38B, 46B, 54B, 62B that is vertically disposed from the corresponding respective top surface 38A, 46A, 54A, 62A, that is in contact with the bottom gel pack assembly 30 at its top side 30A.

The side gel pack assemblies 38, 46, 54, 62 further have a front side or outer side 38C, 46D, 54E, 62F and a back side or inner side 38D, 46C, 54F, 62E which is longitudinally disposed from a front side 38C, 46D, 54E, 62F, and a first side 38E, 46F, 54C, 62D that is transversely opposed to a second side 38F, 46E, 54D, 62C. The front side 38C, 46D, 54E, 62F is abutted against the respective rear sides 34D, 42C, 50F, 58E of the side insulating panels 34, 42, 50, 58. It should be noted that the gel pack assemblies 38, 46, 54, 62 are free of any vents in the exemplary embodiment. In further embodiments, vents may be present. In the exemplary embodiment, the side gel pack assemblies 38, 46, 54, 62 is made of single walled corrugated cardboard, though thicknesses may vary based on load amount, thermal resistivity, ultimate pricing, and stacking concerns.

The back side 38D of the side gel pack assembly 38 abuts and is operatively connected to the first side 54C of the side gel pack assembly 38 and the second side 62C of the side gel pack assembly 62. While the back side 46C of the side gel pack assembly 54 abuts and is operatively connected to the first side 54D of the side gel pack assembly 54 and the second side 62D of the side gel pack assembly 62.

The thermal buffer pads 40, 48, 56, 64 each have a body with a respective top surface 40A, 48A, 56A, 64A, that is in contact with top thermal buffer pad 24 at its underside 24B. The thermal buffer pads 40, 48, 56, 64 are positioned 90 degrees to one another and form a rectangle or square shape. Further the thermal buffer pads have a respective bottom surface 40B, 48B, 56B, 64B that is vertically disposed from the corresponding respective top surface 40A, 48A, 56A, 64A, that is in contact with the bottom thermal buffer pad 32 at its top side 32A.

The thermal buffer pads 40, 48, 56, 64 further have a front side or outer side 40C, 48D, 56E, 64F and a back side or inner side 40D, 48C, 56F, 64E which is longitudinally disposed from a front side 40C, 48D, 56E, 64F, and a first side 40E, 48F, 56C, 64D that is transversely opposed to a second side 40F, 48E, 56D, 64C. The front side 40C, 48D, 56E, 64F is abutted against the respective rear sides 34D, 42C, 50F, 58E of the side insulating panels 34, 42, 50, 58. In the exemplary embodiment, the thermal buffer pads 40, 48, 56, 64 is made of double walled corrugated cardboard, though thicknesses may vary based on load amount, thermal resistivity, ultimate pricing, and stacking concerns.

The back side 40D of the side thermal buffer pad 40 abuts and is operatively connected to the first side 56C of the side thermal buffer pad 40 and the second side 64C of the side thermal buffer pad 64. While the back side 48C of the side thermal buffer pad 56 abuts and is operatively connected to the first side 56D of the side thermal buffer pad 56 and the second side 64D of the side thermal buffer pad 64. A chamber 66 is thereby created by the back side or inner sides 40D, 48C, 56F, 64E and the top 32A thermal buffer pad 32 and the bottom 24B of the thermal buffer pad 24 in the shape of a square or rectangular prism.

Referring now to FIG. 2, a rear side elevation view of the exemplary master pallet shipper apparatus 10 is shown. In this view, the rear 10D can be shown along with the reinforced regions R2 as the outer shroud 42 wraps around the further outer shroud 58. Referring now to FIG. 3, a right side 10E elevation view of the exemplary master pallet shipper apparatus 10 is shown. In this view, the reinforcement region R1 is shown as the front outer shroud 34 wraps around the further router shroud 50. Referring specifically to FIG. 4, a front right section view of the exemplary master pallet shipper apparatus 10 is shown. In this view, the outer shroud 34 is shown by itself along with the reinforcement W1 along with the 90-degree bend where the outer shroud 34 turns into the outer shroud 58.

Referring specifically to FIG. 5-FIG. 8C a perspective view of the exemplary base 68 of a top 18, bottom 28, or side insulating panel 36, 44, 52, 60 of the exemplary master pallet shipper apparatus 10 and its assembly is shown. Referring specifically to FIG. 5, as this may be the construction of any of the panels listed, 18, 28, 36, 44, 52, 60 it will be given a single identifier “P” for the sake of brevity and ease of understanding.

The insulating panel base 68 has an exterior facing side 68A and an interior facing side 68B. Further there are two exterior walls 68C, 68D in the shape of an elongated U where a tab “T”, is overlapped and operatively connected by the further exterior walls 68E, 68F to create stability. In one embodiment, the operative connection is adhesive. In a further exemplary embodiment the tab “T” may not exist and the panel base may be a single unibody member. In yet another embodiment, there may be a tab on every exterior wall.

Referring specifically to FIG. 6, a front right perspective view of an assembled exemplary baffle assembly 70 of the exemplary master pallet shipper apparatus 10 is shown. The baffle assembly 70 is a flat blank that folds to create a four chamber baffle to receive dense pack, loose fill cellulose fiber. Dense pack cellulose is traditionally 3.5 to 4.5 pounds per cubic foot (PCF) in density. Loose fill cellulose is unique in that it does not require any poly binders which may increase cost or prevent the material from being recycled. Further, there are no fire retardants such as boric acid or ammonium sulfate needed within the cellulose. Many prior art solutions may be manufactured using such poly binders such as polyethylene or polypropylene and/or fire retardants such as boric acid or ammonium sulfate. Both of these types of manufacturing additives render these systems ineligible for curbside recycling programs in the United States and eliminate them from ASTM D6400 Compliance. The loose fill cellulose further reduces the shifting and settling of fibers and creates a minimum settled density of 3.5 pounds PCF, insuring a consistent conductive R value throughout the insulating panels “P” necessary to meet rigors of the thermal testing requirements. In an exemplary embodiment, the wall thickness of the exterior walls 68C, 68D, 68E, 68F should have a thickness of greater than about 2 inches. In an exemplary embodiment the distance is 2 inches.

This baffle assembly 70 has a plurality of tabs 70A, that create a plurality of apertures 70B when engaged, along with a plurality of ribs 70C with stanchions 70D on a first end 70E and a second end 70F. The plurality of tabs 70A may be pre broken and folded to support the ribs or may be done by a user or equipment. This allows the baffles to secure the ribs in a 90-degree position. The ribs 70C along with the stanchions 70D are operative to support weight along with dividing insulating material.

Referring specifically to FIG. 7, is a front right perspective view of an insulating panel “P” cover 72 of the exemplary master pallet shipper apparatus 10 is shown. The cover 72 has an exterior facing side 72A and an interior facing side 72B. Further there are two exterior walls 72C, 72D in the shape of an elongated U where a tab “T”, is overlapped and operatively connected by the further exterior walls 72E, 72F to create stability. In a further exemplary embodiment the tab “T” may not exist and the panel base may be a single unibody member. In yet another embodiment, there may be a tab on every exterior wall.

Referring specifically to FIG. 8A, a front right perspective view of the exemplary insulating panel base 68 with the baffle assembly 70 inserted into the base. The stanchions 70D at the first end 70E abut the exterior wall 68E and the stanchions 70D at the second end 70F abut the exterior wall 68F. The plurality of ribs 70C each define a channel 70G for insulating material to be inserted into.

Continuing on to FIG. 8B is a front right perspective view of the insulating panel base 68 with the baffle assembly 70 inserted and packing or insulating material inserted 74 into the cover of the exemplary master pallet shipper apparatus 10. In an exemplary embodiment the packing or insulating material 74 may be cellulose. The insulating material 74 fills the channels 70G defined by the ribs 70C. Referring now to FIG. 8C, the cover 72 is placed “A” onto the insulating panel base 68 with the baffle assembly 70 filled with packing or insulating material 74 and a completed panel “P” is made.

Referring now to FIG. 5, FIG. 7, and FIG. 9-10B, a perspective view of an exemplary base 76 of a top gel pack assembly 22, a bottom gel pack assembly 30, or side gel pack assembly 38, 46, 54, 62, of the exemplary master pallet shipper apparatus 10 and its assembly is shown. Referring specifically to FIG. 5, as this may be the construction of any of the gel pack assembly listed or those listed in the future including 22, 30, 38, 46, 54, 62 it will be given a single identifier “G” for the sake of brevity and ease of understanding. As the base seen in FIG. 5 may also act as the base for the gel pack assemblies “G”, it further has exterior facing sides 76A and an interior facing side 76B. Further there are two exterior walls 76C, 76D in the shape of an elongated U where a tab “T”, is overlapped and operatively connected by the further exterior walls 76E, 76F to create stability. In one embodiment, the operative connection is adhesive.

Referring specifically to FIG. 9, a front right perspective view of a gel pack insert grid 78 of the exemplary master pallet shipper apparatus 10 is shown. The gel pack insert grid 78 contains a plurality of vertical ribs 78A and a plurality of horizontal ribs 78B. The vertical ribs 78A stretch from a first end 78C to a second send 78D while the horizontal ribs stretch from a first end 78E to a second end 78F. In an exemplary embodiment the pack insert grid 78 is made of triple walled corrugated cardboard, though thicknesses may vary based on load amount, thermal resistivity, ultimate pricing, and stacking concerns. In an exemplary embodiment there may be a plurality of gel pack apertures 78G. In a further exemplary embodiment this number is 12. In yet another exemplary embodiment this number is 9.

Referring specifically to FIG. 7, is a front right perspective view of gel pack assembly “G” cover 80 of the exemplary master pallet shipper apparatus 10 is shown. The cover 80 has an exterior facing side 80A and an interior facing side 80B. Further there are two exterior walls 80C, 80D in the shape of an elongated U where a tab “T”, is overlapped and operatively connected by the further exterior walls 80E, 80F to create stability.

Continuing on to FIG. 10A, a is a front right perspective view of two gel pack insert grids 78 placed into a gel pack insert base 76 with gel packs 82 being inserted into the exemplary master pallet shipper apparatus 10 is shown. In this view, the gel pack insert grid 78 has been inserted into the base 76 and the first end 78C if the vertical ribs 78A abuts the exterior wall 76E and the second end 78D of the vertical ribs 78A abuts the exterior wall 76F. Further, the first end 78E of the horizontal ribs 78B abuts the wall 76C and the second end 78F of the horizontal ribs 78B abuts the wall 76D. In an exemplary embodiment, at least one gel pack insert grid 78 is stacked on top of each other. In a further embodiment, two gel pack insert grids 78 are stacked on top of each other. In yet another embodiment, four gel pack insert grids 78 are stacked on top of each other. The plurality of gel packs 82 are places into their respective apertures within the grid.

Continuing on to FIG. 10B, the cover 80 is placed “B” onto the exemplary base 76 of a top gel pack assembly with gel pack insert grid 78 filled with a plurality of gel packs 82 and a completed panel “G” is constructed. The gel pack insert grid 78 assists to keep the plurality of gel packs 82 from shifting during transportation of the apparatus. The plurality of gel packs 82 may be stored at any desired temperature in order to help the apparatus 10 stay at a constant temperature. In one embodiment the plurality of gel packs 82 are gels that may be frozen or refrigerated prior to deploying the apparatus 10.

Referring to FIG. 11-FIG. 13, various thicknesses of cardboard is shown. FIG. 11 shows single thickness corrugated cardboard. In contrast, FIG. 12 shows double thickness corrugated cardboard. Further, FIG. 13 shows triple thickness corrugated cardboard. These cardboards are merely exemplary and ultimate design and visual appearance may differ from manufacturer to manufacturer.

Referring now to FIG. 14-FIG. 16 diagrammatic section views of the exemplary apparatus 10. In these views, a further gel pack assembly 84 is located within the chamber 66. This gel pack assembly 84, is of a slightly smaller size when compared to the other gel packs as it is located within them. As such, the grid is of a slightly different size but may function identically to the grid 78 in the previous gel pack assemblies. Further within these views, insulation panels “P” have been shown as stippling and gel pack assemblies “G” have been shown as hatching for clarity. The gel pack assembly 84 is further surround by buffer pads 86, 88. The buffer pads have top sides 86A, 88A and bottom sides 86B, 88B. Further, in this view cargo 90 has been added to the apparatus. The buffer pads directly abut the cargo 90 at their top 86A and bottom 88B. In this embodiment, there are twelve different pieces of cargo, though this will depend exclusively on the type of cargo desired to be transferred by a user of the apparatus 10 and the time frame needed to ship said cargo to its destination.

Within the specification, when pieces or parts are attached it may occur in any suitable manner, including, but not limited to, being connected at different locations and being connected via a chemical bond, such as a recyclable adhesive, or similar. Further, in one embodiment the insulating material 74 may be made out of a recyclable material, such as loose fill cellulose. In another example, the insulating material 74 may be made out of loose fill plant-based fibers and blends, such as cotton fiber, jute fiber or other similar loose fill plant based fibers. Although the insulating material 74 has been described as being made out of particular materials, the insulating material 74 may be made out any suitable recyclable insulating materials.

In one example, the insulating material 74 may be filled via a weight-based filling process which deposits a fiberized and metered amount of the insulating material 74 into the insulating panel base 68. Further, in an exemplary embodiment all parts of the apparatus 10 may be made out of a recyclable material, such as kraft paper, which may be defined as paper or paperboard (i.e. cardboard) produced from chemical pulp. More particularly, kraft paper may be made by converting wood into wood pulp, which includes cellulose fibers. In alternative embodiments the materials of the apparatus may be made of any suitable recyclable materials that have advantageous thermal properties.

Many components in the exemplary embodiment are described as having multiple thicknesses of walls. These multi-wall corrugated cardboard or fiberboard sheets create a thermal transfer layer, reducing the rate of the cargo temperature change, for more severe ambient temperature environments and/or longer transit times.

Having thus described an exemplary non-limiting configuration of the apparatus 10, its operation will be discussed with reference to some exemplary features used with the various embodiments.

Referring now to FIG. 17, a graph 100 showing the results of the apparatus 10 is shown. In the exemplary embodiment, the temperature 104 may be maintained between about approximately two degrees Celsius 106 and eight degrees Celsius 108 over the course of 144 hours, or one week, in an environment that varied between about 28 to about 35 degrees Celsius 102. However, it should be noted that the temperature may be maintained in any between any desired temperature range. As can be seen, the cargo never reached above 5 degrees Celsius. As such, the apparatus 10 may maintain proper temperatures up to about 10 to 12 days using an external temperature of 28 to 35 degrees Celsius.

In one example, the apparatus 10 may be integrally formed via fully automated carton erector equipment and sealing equipment via hot melt, cold set adhesive, contact adhesive or the like. In another embodiment, it may be assembled by relatively unskilled laborers. Further, where parts or pieces are described as abutting or in contact with one another, glue or other similarly situated adhesives may be added to bring the various parts in semi-permanent engagement. The exception to this includes the top pieces which include the top cap 16, the top insulating panel 18, the top plug 20, the top gel pack assembly 22, and the top thermal buffer pad 24 being adhered to any of the side panel pieces including the outer shrouds 34, 42, 50, 58, the side insulating panels 36, 44, 52, 60, the side gel pack assemblies 38, 46, 54, 62, and the thermal buffer pads 40, 48, 56, 64.

The apparatus 10 may be put together using an exemplary method in accordance with the present disclosure. In an exemplary embodiment, a method of creating an insulated pallet shipper is disclosed. In this embodiment the method describes the operation of the apparatus 10. In one embodiment, the method may include providing at least one outer shroud, a plurality of insulating panels, a plurality of gel pack assemblies, a plurality of thermal buffer pads, a top assembly and a bottom assembly. The method may further include assembling the container to provide a chamber, removing a side, inserting in cargo insulating the cargo to keep a temperature within the apparatus within a range of temperatures. The method may further include providing an additional gel pack assembly within the chamber. The plurality of gel pack assemblies may be filled with recyclable gel packs that resist temperature change. Further, the top assembly may contain a top cap, at least one top insulating panel, a top plug, at least one top gel pack assembly, and at least one top thermal buffer pad. Additionally, the bottom assembly may contain a bottom cap, at least one bottom insulating panel, at least one bottom gel pack assembly, and at least one bottom thermal buffer pad.

The method may further include positioning at least one of the plurality of insulating panels adjacent the at least one outer shroud. Further, the at least one insulating panel may be positioned between the at least one piece of outer shroud and at least one of the plurality of gel pack assemblies. The at least one of the plurality of gel pack assemblies may be individually positioned or multiply positioned between at least one of the plurality insulating panels. The at least one of the plurality of insulating panels may be placed interior the at least one of the plurality of gel pack assemblies. All of these may be glued or otherwise coated with adhesive to attach the pieces together. Although a particular method of forming the insulated liner 10 has been described, it is envisioned that the insulated liner 10 may be formed by any suitable method.

Various inventive concepts may be embodied as one or more methods, of which an example has been provided. The acts performed as part of the method may be ordered in any suitable way. Accordingly, embodiments may be constructed in which acts are performed in an order different than illustrated, which may include performing some acts simultaneously, even though shown as sequential acts in illustrative embodiments.

While various inventive embodiments have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and/or structures for performing the function and/or obtaining the results and/or one or more of the advantages described herein, and each of such variations and/or modifications is deemed to be within the scope of the inventive embodiments described herein. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the inventive teachings is/are used. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific inventive embodiments described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, inventive embodiments may be practiced otherwise than as specifically described and claimed. Inventive embodiments of the present disclosure are directed to each individual feature, system, article, material, kit, and/or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and/or methods, if such features, systems, articles, materials, kits, and/or methods are not mutually inconsistent, is included within the inventive scope of the present disclosure.

The articles “a” and “an,” as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean “at least one.” The phrase “and/or,” as used herein in the specification and in the claims (if at all), should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and/or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the “and/or” clause, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to “A and/or B”, when used in conjunction with open-ended language such as “comprising” can refer, in one embodiment, to A only (optionally including elements other than B); in another embodiment, to B only (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc. As used herein in the specification and in the claims, “or” should be understood to have the same meaning as “and/or” as defined above. For example, when separating items in a list, “or” or “and/or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of” or “exactly one of,” or, when used in the claims, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e. “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.” “Consisting essentially of,” when used in the claims, shall have its ordinary meaning as used in the field of patent law.

As used herein in the specification and in the claims, the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements may optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, “at least one of A and B” (or, equivalently, “at least one of A or B,” or, equivalently “at least one of A and/or B”) can refer, in one embodiment, to at least one, optionally including more than one, A, with no B present (and optionally including elements other than B); in another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including elements other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other elements); etc.

When a feature or element is herein referred to as being “on” another feature or element, it can be directly on the other feature or element or intervening features and/or elements may also be present. In contrast, when a feature or element is referred to as being “directly on” another feature or element, there are no intervening features or elements present. It will also be understood that, when a feature or element is referred to as being “connected”, “attached” or “coupled” to another feature or element, it can be directly connected, attached or coupled to the other feature or element or intervening features or elements may be present. In contrast, when a feature or element is referred to as being “directly connected”, “directly attached” or “directly coupled” to another feature or element, there are no intervening features or elements present. Although described or shown with respect to one embodiment, the features and elements so described or shown can apply to other embodiments. It will also be appreciated by those of skill in the art that references to a structure or feature that is disposed “adjacent” another feature may have portions that overlap or underlie the adjacent feature.

Spatially relative terms, such as “under”, “below”, “lower”, “over”, “upper”, “above”, “behind”, “in front of”, and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if a device in the figures is inverted, elements described as “under” or “beneath” other elements or features would then be oriented “over” the other elements or features. Thus, the exemplary term “under” can encompass both an orientation of over and under. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. Similarly, the terms “upwardly”, “downwardly”, “vertical”, “horizontal”, “lateral”, “transverse”, “longitudinal”, and the like are used herein for the purpose of explanation only unless specifically indicated otherwise.

Although the terms “first” and “second” may be used herein to describe various features/elements, these features/elements should not be limited by these terms, unless the context indicates otherwise. These terms may be used to distinguish one feature/element from another feature/element. Thus, a first feature/element discussed herein could be termed a second feature/element, and similarly, a second feature/element discussed herein could be termed a first feature/element without departing from the teachings of the present invention.

An embodiment is an implementation or example of the present disclosure. Reference in the specification to “an embodiment,” “one embodiment,” “some embodiments,” “one particular embodiment,” or “other embodiments,” or the like, means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least some embodiments, but not necessarily all embodiments, of the invention. The various appearances “an embodiment,” “one embodiment,” “some embodiments,” “one particular embodiment,” or “other embodiments,” or the like, are not necessarily all referring to the same embodiments.

If this specification states a component, feature, structure, or characteristic “may”, “might”, or “could” be included, that particular component, feature, structure, or characteristic is not required to be included. If the specification or claim refers to “a” or “an” element, that does not mean there is only one of the element. If the specification or claims refer to “an additional” element, that does not preclude there being more than one of the additional element.

As used herein in the specification and claims, including as used in the examples and unless otherwise expressly specified, all numbers may be read as if prefaced by the word “about” or “approximately,” even if the term does not expressly appear. The phrase “about” or “approximately” may be used when describing magnitude and/or position to indicate that the value and/or position described is within a reasonable expected range of values and/or positions. For example, a numeric value may have a value that is +/−0.1% of the stated value (or range of values), +/−1% of the stated value (or range of values), +/−2% of the stated value (or range of values), +/−5% of the stated value (or range of values), +/−10% of the stated value (or range of values), etc. Any numerical range recited herein is intended to include all sub-ranges subsumed therein.

Additionally, any method of performing the present disclosure may occur in a sequence different than those described herein. Accordingly, no sequence of the method should be read as a limitation unless explicitly stated. It is recognizable that performing some of the steps of the method in a different order could achieve a similar result.

In the claims, as well as in the specification above, all transitional phrases such as “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” “holding,” “composed of,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of” and “consisting essentially of” shall be closed or semi-closed transitional phrases, respectively, as set forth in the United States Patent Office Manual of Patent Examining Procedures.

In the foregoing description, certain terms have been used for brevity, clarity, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed.

Moreover, the description and illustration of various embodiments of the disclosure are examples and the disclosure is not limited to the exact details shown or described. 

What is claimed:
 1. An insulated pallet shipper apparatus wherein: the apparatus has a width of about 40 inches; the apparatus has a length of about 48 inches; the apparatus has a height of about 50 inches; the apparatus is six sided and closed; and the apparatus is adapted to sit on a pallet for transportation.
 2. The apparatus of claim 1, wherein the entire apparatus is fully recyclable.
 3. A fully insulated and fully recyclable apparatus comprising: an outer shroud; a top assembly; a bottom assembly; a plurality of insulating panels; a plurality of thermal resistive assemblies; and a plurality of thermal buffer pads.
 4. The apparatus of claim 3, wherein the plurality of insulating panels are filled with loose fill cellulose insulation with a settled distance of about 3.5 pounds PCF or greater free of fire retardant additives or poly binders.
 5. The apparatus of claim 4, wherein the plurality of insulating panels each have a wall thickness of two inches or greater.
 6. The apparatus of claim 3, wherein the plurality of thermal resistive assemblies are non-vented.
 7. The apparatus of claim 3, wherein the thermal buffer pads are double walled cardboard.
 8. The apparatus of claim 3, wherein the plurality of thermal resistive assemblies each contain at least one biodegradable and recyclable gel pack.
 9. The apparatus of claim 3, wherein the top assembly includes: a top cap, at least one top insulating panel, a top plug, at least one top thermal resistive assembly, and at least one top thermal buffer pad.
 10. The apparatus of claim 9, wherein the top cap is fixedly attached to a top insulating panel, the top insulating panel is fixedly attached to the top plug, the top plug is fixedly attached to a top thermal buffer pad.
 11. The apparatus of claim 3, wherein the bottom assembly includes: a bottom cap, at least one bottom insulating panel, at least one bottom thermal resistive assembly, and at least one bottom thermal buffer pad.
 12. The apparatus of claim 11, wherein the bottom cap is fixedly attached to a bottom insulating panel, the bottom insulating panel is fixedly attached to a top thermal buffer pad.
 13. The apparatus of claim 12, wherein the outer shroud comprises four sides, each side containing: at least one side insulating panel, at least one side thermal resistive assembly, and at least one side thermal buffer pad.
 14. The apparatus of claim 13, wherein the outer shroud is fixedly attached to a side insulating panel, the side insulating panel is fixedly attached to a thermal resistive assembly and the thermal resistive assembly is fixedly attached to a side thermal buffer pad.
 15. The apparatus of claim 14, wherein the outer shroud is not in fixed engagement with the top assembly.
 16. The apparatus of claim 15, wherein a chamber operative to accept cargo is formed by the attachment of the outer shroud to the bottom assembly.
 17. The apparatus of claim 16, wherein at least one thermal resistive assembly is located within the chamber.
 18. The apparatus of claim 17, wherein the plurality of thermal resistive assemblies each contain at least one biodegradable and recyclable gel pack.
 19. The apparatus of claim 18, wherein the apparatus is operative to carry cargo that is desired to be kept at a near constant temperature.
 20. The apparatus of claim 19, wherein the apparatus is operative to hold the cargo in a temperature range of about 2 degrees Celsius to about 8 degrees Celsius for over 120 hours. 